Discharge nozzle having a tubular outlet section containing vanes - Patent Application 20070122997

Abstract

1. A nozzle and method suitable for dispensing a liquid foamable product, particularly useful with a carbon dioxide foaming agent, the nozzle including a tubular outlet section having an inlet portion and an outlet portion, the tubular outlet section having an inner wall surface defining a discharge passageway having a centerline axis, the tubular outlet section further including a plurality of vanes mounted on the inner wall surface parallel to the centerline axis, the vanes extending radially within the discharge passageway, the vanes having length, thickness, and width dimensions, the vanes not connecting or touching at the centerline of the discharge passageway.

Description

[Technical Field]

[0001] FIELD OF THE INVENTION. The present invention relates to an improved discharge nozzle suitable for applying spray foam and a device including the same, and in particular to satisfactorily applying spray foam in an environmentally friendly manner. The discharge nozzle is particularly suitable for applying spray foam using a carbon dioxide blowing agent and can be used with two-component spray foam. [Background technology]

[0002] 2. Description of the Prior Art: Many existing blowing agents used in the dispensing and foaming of one- and two-component spray foams, particularly two-component low-pressure (TCLP) spray foams, are undesirable due to their high global warming potential (GWP) properties. These undesirable blowing agents are primarily hydrofluorocarbon (HFC)-based. Low-GWP hydrofluoroolefin (HFO) alternatives have been explored as potential replacements for HFC blowing agents. However, it has been found that HFO alternatives can react with catalysts used in some spray foams, potentially reducing foam performance and even raising industrial hygiene concerns.

[0003] Although a more desirable blowing agent is carbon dioxide (CO), CO presents its own challenges when used to dispense foam. Carbon dioxide is less soluble in foam-making chemicals than either HFCs or HFOs. This means that less of the blowing agent (CO) is present in the foam-making chemicals, resulting in reduced foaming in the dispensed foam. Therefore, when CO is used as a blowing agent, the foam mixture will be sprayed in larger droplets and contain more liquid than foam mixtures sprayed using HFC or HFO alternatives. Therefore, the dispensed foam mixture tends to be sprayed in a concentrated stream with splashes rather than a well-dispersed atomized spray pattern.

[0004] There is a need for a nozzle suitable for dispensing liquid foamable products that has features that improve the spray pattern of the foam mixture when applied to a surface. Such a nozzle would be particularly desirable when environmentally friendly, but perhaps less than ideal, blowing agents such as CO2 are used, and would be particularly useful for applying two-component spray foams. Summary of the Invention [Means for solving the problem]

[0005] The present invention provides a nozzle suitable for dispensing a liquid foamable product, comprising a tubular outlet section having an inlet portion and an outlet portion, the tubular outlet section has an inner wall surface defining a discharge passageway, the passageway having a centerline axis, the tubular outlet section further having a plurality of vanes attached to the inner wall surface parallel to the centerline axis, the vanes extending radially into the discharge passageway, the vanes having a length having a length dimension, a thickness having a thickness dimension, and a width having a width dimension, the thickness dimension being less than the width dimension, the width dimension being less than the length dimension, the length dimension being a distance at which the vane meets the inner wall surface parallel to the centerline axis, the thickness dimension being an effective thickness of the vane at the inner wall surface perpendicular to the centerline axis, and the width dimension being a distance from the inner wall surface at which the vane extends into the discharge passageway, and the vanes do not meet or meet at the centerline of the discharge passageway.

[0006] The present invention also provides a method of dispensing a liquid foamable product using a nozzle including a tubular outlet section having an inlet portion and an outlet portion, comprising: a) delivering a liquid foamable product, the product comprising at least one foaming agent, to an inlet of a tubular outlet section, the tubular outlet section having an inner wall surface defining a discharge passageway, the passageway having a centerline axis, the tubular outlet section further having a plurality of vanes mounted on the inner wall surface parallel to the centerline axis, the vanes extending radially within the discharge passageway, the vanes having a length having a length dimension, a thickness having a thickness dimension, and a width having a width dimension, the thickness dimension being less than the width dimension and the width dimension being less than the length dimension; the length dimension is the distance the vane contacts the inner wall surface parallel to the centerline axis, the thickness dimension is the effective thickness of the vane at the inner wall surface perpendicular to the centerline axis, and the width dimension is the distance from the inner wall surface that the vane extends into the discharge passageway, the vane not connecting or contacting at the centerline of the discharge passageway; b) discharging the liquid foamable product from the outlet of the tubular outlet section; The present invention relates to a method, including: [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a diagram of one embodiment of a tubular outlet section that splits the foamable mixture into separate streams while simultaneously increasing shear on the foamable mixture. [Figure 2] 2 is a detail of the tubular outlet section of FIG. 1 showing an embodiment in which the tubular outlet section outlet portion terminates at the outlet plane of the discharge nozzle and the vanes terminate in the plane of the outlet plane, i.e., the vanes are flush with the plane of the outlet plane, the width dimension of each vane has a maximum value at the outlet portion or plane of the outlet face of the tubular outlet section, the width dimension decreases in value along the vane, parallel to the length of the vane, away from the outlet face, and the thickness dimension decreases in value along the vane, parallel to the length of the vane, away from the outlet face. [Figure 3] 1A-1C are diagrams of triangular vanes having lengths, thicknesses, and widths showing the associated length, thickness, and width dimensions, including various vane thickness embodiments. [Figure 4] 1 is a general depiction of a prior art discharge nozzle having a tubular outlet section that is essentially a hollow tube. FIG. [Figure 5] FIG. 1 is a cross-sectional view of an embodiment of a discharge nozzle having a mixing chamber suitable for two-component spray foam attached to the inlet of a tubular outlet section having vanes. [Figure 6] 6 is an end view of the discharge nozzle of FIG. 5 showing an embodiment having six vanes distributed radially symmetrically about the centerline of the discharge passage. FIG. [Figure 7] FIG. 7 is a perspective view of the discharge nozzle of FIGS. 5 and 6 having a relatively transparent or see-through housing. [Figure 8] FIG. 1 is a diagram of one type of spray gun that may include a discharge nozzle having a tubular outlet section with vanes. [Figure 9] FIG. 1 is a diagram of an undesirable spray pattern produced from a combination of two-component foam and CO2 blowing agent using a discharge nozzle with a tubular outlet section that is essentially a hollow tube without vanes. [Figure 10] FIG. 1 is a diagram of a desirable spray pattern produced from a combination of two-component foam and CO2 blowing agent using a discharge nozzle having a tubular outlet section with vanes radially symmetrically distributed within the tubular outlet section. DETAILED DESCRIPTION OF THE INVENTION

[0008] FIG. 4 provides a general depiction of a prior art discharge nozzle 40, also referred to as a "mixing and dispensing nozzle" or "anti-crossover or crossover-resistant nozzle" (U.S. Pat. No. 6,021,961 to Brown) or "mixing device" (U.S. Pat. No. 10,322,385 to Schulz et al.). Both the "mixing and dispensing nozzle" and the "mixing device" are designed to be discharge nozzles used in spray guns, which have a gun body, handle, trigger, and other associated components useful in spray guns for spraying foam. The discharge nozzle 40 shown in FIG. 4 is useful for combining and mixing at least two components and then dispensing what is known as a two-component spray foam. Traditionally, two-component spray foams are typically made by combining an "A component" and a "B component."

[0009] As shown in FIG. 4, a discharge nozzle 40 typically includes a housing 41 defining a chamber 42, which is a mixing chamber that may have various internal components to facilitate mixing of the components. The discharge nozzle further includes an inlet 43 for supplying component A to the mixing chamber and another inlet 44 for supplying component B to the mixing chamber; other inlets (not shown) for other materials may be present, if desired. The housing 41 and chamber 42 are generally cylindrical or elongated in shape, with the supply inlets 43 and 44 at one end and an outlet opening at the opposite end 45. The discharge nozzle also includes a tubular outlet section 46 having an inlet portion 47 and an outlet portion 48. In the particular discharge nozzle shown in FIG. 4, the inlet portion 47 of the tubular outlet section 46 is connected to the housing 41 via a transition section 49 having a generally trapezoidal shape. FIG. 4 provides further details of the prior art tubular outlet section 46. As shown in this detail, the tubular outlet section is essentially a hollow tube.

[0010] It has been found that when using a discharge nozzle such as that shown in FIG. 4 to spray foam using certain gas blowing agents such as CO, the foam mixture is discharged as a concentrated stream of unacceptably large droplets rather than a well-dispersed spray pattern of more atomized droplets.

[0011] Furthermore, it has been unexpectedly found that modifying the outlet portion of the tubular exit section of the discharge nozzle to split the foamable mixture into separate streams while simultaneously increasing shear on the foamable mixture reduces droplet size, increases foaming of the foam mixture, and improves distribution of the atomized droplets in the intended spray pattern.

[0012] The present invention therefore relates to a nozzle suitable for dispensing a liquid foamable product, the nozzle comprising a tubular outlet section having an inlet portion and an outlet portion, the tubular outlet section having an inner wall surface defining a dispensing passageway, the passageway having a centerline axis, the tubular outlet section further comprising a plurality of vanes attached to the inner wall surface parallel to the centerline axis, the vanes extending radially into the dispensing passageway, the vanes having a length having a length dimension, a thickness having a thickness dimension, and a width having a width dimension, the thickness dimension being less than the width dimension, the width dimension being less than the length dimension, the length dimension being the distance at which the vane meets the inner wall surface parallel to the centerline axis, the thickness dimension being an effective thickness of the vane at the inner wall surface perpendicular to the centerline axis, and the width dimension being the distance from the inner wall surface at which the vane extends into the dispensing passageway, the vanes not meeting or contiguous at the centerline of the dispensing passageway.

[0013] The terms "nozzle" and "discharge nozzle" are used interchangeably herein. Furthermore, the nozzles described herein are not intended to be limited to "mixing and discharge nozzles" or "anti-crossover or crossover-resistant nozzles" for use with spray guns, which are preferred embodiments. It is contemplated that the principles described herein relating to a tubular outlet section having multiple vanes may be used at the outlet of virtually any device used to spray foam, and thus the terms "nozzle" or "discharge nozzle" are intended to include substantially any device suitable for spraying any foam composition that further has an outlet passageway including a tubular outlet section having multiple vanes as disclosed or configured herein.

[0014] One embodiment of a tubular outlet section that divides the foamable mixture into separate streams while simultaneously increasing shear on the foamable mixture is shown in Figures 1 and 2. A nozzle (not fully shown) includes a tubular outlet section 1 having an inlet section 2 and an outlet section 3. The tubular outlet section has an inner wall surface 4 that defines a hollow discharge passageway 5 through the tubular outlet section, the passageway having a centerline axis 6. The tubular outlet section further includes a plurality of vanes 7 mounted on the inner wall surface parallel to the centerline axis, the vanes extending radially into the discharge passageway 5. The tubular outlet section can have a constant diameter throughout, or can narrow from a larger diameter at the inlet section to a slightly smaller diameter at the outlet, or, as shown in Figures 1 and 2, the diameter of the tubular outlet section can decrease slightly from the inlet section 2 to the beginning of the vanes 9, and then the diameter increases from the beginning of the vanes 9 to the outlet section 3. In some preferred embodiments, the diameter does not vary by more than 5% from the inlet section to the outlet section.

[0015] Each vane 7 has a length, a thickness, and a width. Furthermore, the thickness dimension is less than the width dimension, which is less than the length dimension. Figure 2 is a cross-sectional perspective view of the outlet portion 3 of the six-vane tubular outlet section 1 taken axially along the centerline axis, showing three of the vanes beginning at point 9 within the tubular passage.

[0016] As shown in Figure 2 and in detail in Figure 3, the vanes 7 are preferably triangular in shape with the longer sides of the vanes parallel to the centerline axis and in contact with the inner wall surface 4. The vane length is characterized by the vane length dimension, which is defined herein as the distance 20 at which the vane contacts the inner wall surface parallel to the centerline axis. Preferably, all vanes have the same length dimension.

[0017] Vane thickness is characterized by a thickness dimension, which is defined herein as the effective thickness of the vane perpendicular to the centerline axis at the inner wall surface. If the vane thickness varies at the inner wall surface along the length of the vane, the effective thickness of the vane is therefore considered to be the maximum thickness dimension of the vane at the inner wall surface along the length of the vane. As shown in FIG. 3, a vane thickness dimension 21a is shown for a vane with rectangular ends, and therefore a thickness at the inner wall surface that is the same as the thickness radially into the passage. Also shown in FIG. 3 is an alternative thickness dimension 21b for a vane with trapezoidal ends, and therefore a larger, different thickness at the inner wall surface, with the vane thickness tapering radially away from the inner wall surface into the passage. In this example, the thickness dimension is the distance perpendicular to the centerline axis at the inner wall surface, as shown in FIG. 3. As the inner wall surface is generally curved, for the avoidance of doubt, the effective thickness is the substantially linear distance of the vane through the point where the vane contacts the inner wall, as shown at reference numeral 21b in Figure 3.

[0018] In some embodiments, the thickness dimension of each vane increases along its length from a minimum at the outlet of the tubular outlet section. One such illustration of this embodiment is shown in FIG. 3, where reference numeral 23a is a top view of a triangular vane 7, showing the vane having a trapezoidal appearance when viewed radially from the centerline axis. In this example, the vane has a minimum thickness dimension at the outlet of the tubular outlet section (or outlet face 25) and a maximum thickness dimension at point 9 within the tubular passage where the vane terminates. In a further aspect of this embodiment, the thickness dimension varies along the length of the vane, but the vane has the same thickness dimension at the inner wall surface as it does radially within the passage. That is, the vane has a combination of the features of reference numeral 23a combined with the features of reference numeral 21a. Yet another aspect is the combination of embodiments encompassed by the combination of reference numerals 23a and 21b. Also shown in Figure 3 is another embodiment 23b, a top view of the triangular vane 7, which shows that the vane has a rectangular appearance when viewed radially from the centerline axis, i.e., the thickness dimension does not vary along the length of the vane. Similarly, in a further aspect of this embodiment, the thickness dimension is the same along the length of the triangular vane 7, and the vane has the same thickness dimension at the inner wall surface as it does radially within the passage. This is a combination of the features of reference numeral 23b and reference numeral 21a. Yet another aspect is the combination of the embodiments encompassed by the combination of reference numerals 23b and 21b.

[0019] Vane width is characterized by a width dimension, defined herein as the maximum distance 22 from the inner wall surface that the vane extends into the discharge passageway. Preferably, each vane is triangular in shape along its length, with the width varying linearly from a maximum at the tubular outlet section outlet (or outlet face 25) to a minimum at the opposite end of the vane (point 9 within the tubular passageway). The vanes also do not connect or meet at the discharge passageway centerline. Preferably, the vanes do not extend radially into the passageway to the centerline axis.

[0020] Preferably, all of the vanes have similar shapes and sizes, i.e., all of the vanes have the same combination of width, thickness, and length dimensions.

[0021] Nozzles suitable for dispensing liquid foamable products include a tubular outlet section having a plurality of vanes mounted on an interior wall surface parallel to a centerline axis, the vanes extending radially into a dispensing passageway. "Plural" means two or more vanes. In some embodiments, the nozzle includes a tubular outlet section having three or more vanes. In some other embodiments, the nozzle includes a tubular outlet section having five to eight vanes, and in some other embodiments, the nozzle includes a tubular outlet section having five to ten vanes. Ten is considered a practical maximum for most foamable compositions.

[0022] A nozzle suitable for dispensing a liquid foamable product includes a tubular outlet section having an inlet portion and an outlet portion, and in some embodiments, the outlet portion of the tubular outlet section is the outlet face of the dispensing nozzle. A vane preferably extends from the outlet end of the tubular outlet section into the tubular outlet section, terminating at a distance (parallel to the centerline) between the inlet and outlet portions of the tubular outlet section. Generally, the vane extends from the outlet portion (or outlet face 25) into the tubular outlet section a distance parallel to the centerline that is about one-third or less of the total length of the tubular outlet section; preferably, the vane extends at a distance parallel to the centerline that is about one-quarter or less of the total length of the tubular outlet section. In the preferred embodiment shown in Figures 1 and 2, the distance parallel to the centerline is measured from the outlet portion (or outlet face 25) to a point 9 within the tubular passage where the vane terminates. Preferably, no vanes are located near or originate at the inlet portion of the tubular outlet section; rather, vanes are present only near the outlet portion of the tubular outlet section. Furthermore, in many cases, it is desirable for the vanes to terminate flush with the outlet face of the discharge nozzle. In other words, the vanes do not extend outside the outlet portion of the tubular outlet section, but rather terminate flush with the outer surface of the tubular outlet section outlet portion, as shown in Figures 1 and 2, where the tubular outlet section outlet portion 3 terminates at the outlet face 25 and the vanes 7 terminate at the plane of the outlet face, i.e., the vanes 7 are preferably flush with the plane of the outlet face.

[0023] In some embodiments, such as those shown in Figures 1 and 2, the width dimension of each vane has a maximum value at the plane of the outlet or outlet face of the tubular outlet section and decreases in value along the length of the vane to point 9 within the tubular passage.

[0024] In some embodiments, the thickness dimension of each vane has a maximum value at the inner wall surface and decreases radially into the discharge passage, as shown in Figure 3 as reference numeral 21b. In some other embodiments, the thickness dimension of each vane does not change from the inner wall surface toward the discharge passage, as shown in Figure 3 as reference numeral 21a.

[0025] In some preferred embodiments, the vanes are distributed radially symmetrically about the centerline of the discharge passageway, however, in some embodiments, the vanes are distributed radially asymmetrically about the centerline of the discharge passageway.

[0026] Although the figures show the vanes positioned within the tubular outlet section with their lengths strictly parallel to the centerline axis and their widths strictly radial to the centerline axis of the tubular outlet section, if desired the vanes may be positioned offset from a truly parallel or radial position to the centerline axis of the tubular outlet section as long as spray performance is not affected.

[0027] Devices suitable for dispensing liquid foamable products, which may include a nozzle having a tubular outlet section with vanes as described herein, include spray components known as "mixing and dispensing nozzles" or "anti-crossover or crossover resistant nozzles" or even "mixing devices." For example, the tubular outlet section may be attached to the outlet of a mixing device, or other nozzles may be modified to include the tubular outlet section as described herein.

[0028] One suitable discharge nozzle combines and mixes a foamable mixture of at least two components, then dispenses what is known as a two-component spray foam. Thus, in one embodiment, a mixing chamber is attached to the inlet of the tubular outlet section, as shown in Figures 5, 6, and 7, a two-component spray foam discharge nozzle modified to include a vaned tubular outlet section. The discharge nozzle typically includes a housing 51 defining a mixing chamber 52, which may have various internal components to facilitate mixing of the components. The discharge nozzle further includes an inlet 53 for supplying component A to the mixing chamber and another inlet 54 for supplying component B to the mixing chamber; if desired, other inlets (not shown) may be present for other foam components or other materials, such as a blowing agent. The housing 51 and chamber 52 are generally cylindrical or elongated, with supply inlets 53 and 54 at one end and an outlet opening 55 at the opposite end. The discharge nozzle further includes a transition piece 59 to a tubular outlet section 56 having an inlet section 57 and an outlet section 58, with vanes in the outlet end of the tubular outlet section.

[0029] FIG. 6 is an end view of a two-component spray foam discharge nozzle 50 as shown in FIG. 5. It shows a discharge nozzle housing 61 connected to a tubular outlet section 62 via a transition piece 63. The discharge nozzle further includes a flange 64 for mounting the nozzle to a spray gun. The tubular outlet section includes six vanes 65 distributed radially symmetrically about the centerline of the discharge passage. The vanes extend into the discharge passage but do not connect or meet at the centerline of the discharge passage. This leaves a hollow, linear section at the centerline of the foamable material discharge passage, and the vanes further divide the foamable material into separate streams. This arrangement of the vanes with a hollow, linear discharge section at the centerline of the passage simultaneously divides the foamable mixture into separate streams while also imparting additional shear to the foamable mixture at the outlet of the tubular outlet section.

[0030] Useful discharge nozzles including a tubular outlet section with vanes include any number of "spray gun nozzles" that may include the tubular outlet section with vanes described herein. One such discharge device in the form of a spray gun 80 is shown in FIG. 8. It is useful for combining and mixing at least two components and then dispensing what is known as a two-component spray foam. As shown in FIG. 8, by way of example, the spray gun 80 typically includes a gun body 81 having one or more inlets 82 for the components to be sprayed, a handle 83, and a trigger 84. Attached to the spray gun 80 is a discharge nozzle 50 for a two-component spray foam, such as those shown in FIGS. 5, 6, and 7, that includes a tubular outlet section with vanes; however, for simplicity, the vanes and other internal details of the discharge nozzle 50 are not shown or reproduced in FIG. 8. Other such devices are possible.

[0031] The present invention also provides a method of dispensing a liquid foamable product using a nozzle including a tubular outlet section having an inlet portion and an outlet portion, comprising: a) delivering a liquid foamable product, the product comprising at least one foaming agent, to an inlet of a tubular outlet section, the tubular outlet section having an inner wall surface defining a discharge passageway, the passageway having a centerline axis, the tubular outlet section further having a plurality of vanes mounted on the inner wall surface parallel to the centerline axis, the vanes extending radially within the discharge passageway, the vanes having a length having a length dimension, a thickness having a thickness dimension, and a width having a width dimension, the thickness dimension being less than the width dimension and the width dimension being less than the length dimension; the length dimension is the distance the vane contacts the inner wall surface parallel to the centerline axis, the thickness dimension is the effective thickness of the vane at the inner wall surface perpendicular to the centerline axis, and the width dimension is the distance from the inner wall surface that the vane extends into the discharge passageway, the vane not connecting or contacting at the centerline of the discharge passageway; b) discharging the liquid foamable product from the outlet of the tubular outlet section; The present invention relates to a method, including:

[0032] In preferred embodiments, the method uses an environmentally friendly blowing agent such as carbon dioxide. In some embodiments, the method further comprises, prior to step a), mixing two or more components to create the liquid foamable product, preferably mixing a two-component foamable product with a blowing agent. Preferably, mixing is accomplished prior to the inlet of the tubular outlet section within the nozzle.

[0033] All of the features and elements of the tubular outlet section described herein can be used in a method of dispensing a liquid foamable product using a nozzle including the tubular outlet section. That is, the tubular outlet section has two or more vanes attached to its inner wall surface parallel to the centerline axis, the vanes extending radially into the discharge passageway. In some embodiments, the nozzle includes a tubular outlet section having three or more vanes. In some other embodiments, the nozzle includes a tubular outlet section having five to eight vanes, and in other embodiments, the nozzle includes a tubular outlet section having five to ten vanes. The method can use a discharge nozzle including a tubular outlet section in which the vanes are distributed radially symmetrically around the centerline of the discharge passageway. Alternatively, the method can use a discharge nozzle including a tubular outlet section in which the vanes are distributed radially asymmetrically around the centerline of the discharge passageway. Furthermore, although the figures show the vanes positioned within the tubular outlet section with their lengths strictly parallel to the centerline axis and their widths strictly radial to the centerline axis of the tubular outlet section, the vanes may be positioned offset from a truly parallel or radial position relative to the centerline axis of the tubular outlet section, if desired, as long as spray performance is not affected.

[0034] As previously described herein, in one embodiment of a method of using a discharge nozzle including a tubular outlet section, each vane is triangular in shape, with the width dimension of each vane having a maximum value at the outlet of the tubular outlet section, decreasing linearly along the length of the vane, and reaching a minimum value at the opposite end of the vane. Similarly, in another embodiment of a method of using a discharge nozzle including a tubular outlet section, the thickness dimension of each vane in the nozzle has a maximum value at the inner wall surface and decreases radially into the discharge passage.

[0035] In one preferred embodiment of a method of using a discharge nozzle including a tubular outlet section, each of the vanes has a minimum thickness dimension at the tubular outlet section outlet (or outlet face 25) and a maximum thickness dimension at a point 9 in the tubular passage where the vane terminates, as shown in Figures 1, 2, and 3. One such illustration of this embodiment is shown in Figure 3, where reference numeral 23a is a top view of a triangular vane 7, indicating a vane that has a trapezoidal appearance when viewed radially from the centerline axis. In this example, the vane has a minimum thickness dimension at the tubular outlet section outlet (or outlet face 25) and a maximum thickness dimension at a point 9 in the tubular passage where the vane terminates.

[0036] In a further aspect of this preferred embodiment, the vane has the same thickness dimension at the inner wall as radially within the passage, although the thickness dimension varies along the length of the vane, i.e., the vane has a combination of the features of reference numeral 23a combined with the features of reference numeral 21a, as shown in Figure 3.

[0037] In another aspect of this embodiment, the thickness dimension varies along the length of the vane, but also decreases radially from the inner wall surface into the passageway, i.e., the vane has a trapezoidal shape when viewed from the end as in Figure 6. This is a combination of the feature of reference numeral 23a combined with the feature of reference numeral 21b, as shown in Figure 3.

[0038] Furthermore, it is generally preferred that all of the vanes have the same size and shape.

[0039] As previously described herein, in one embodiment of a method of using a discharge nozzle including a tubular outlet section, the discharge nozzle further includes a mixing chamber attached to the inlet portion of the tubular outlet section, and in yet another embodiment of a method of using a discharge nozzle including a tubular outlet section, the outlet portion of the tubular outlet section of the nozzle is the outlet face of the nozzle. [Example]

[0040] A spray gun with a discharge nozzle having a hollow tubular outlet section without vanes was used as a control, and then a spray gun with a discharge nozzle similar to those shown in Figures 5, 6, and 7, having six vanes, was used to spray two-component foam onto a flat, horizontal substrate using CO2 blowing agent. The foaming chemical, substrate, and ambient temperatures were all between 70 and 80 degrees Fahrenheit. The nozzle end was located 18 to 24 inches from the substrate.

[0041] Figure 9 is an illustration of an undesirable spray pattern produced from a combination of two-component foam and CO blowing agent using a discharge nozzle with a tubular outlet section, essentially a hollow tube without vanes. The resulting foam piled up in the center, had unacceptable splashing, resulted in a visually uneven spray pattern, and had poor adhesion to the substrate.

[0042] Figure 10 is an illustration of a desirable spray pattern produced from a combination of two-component foam and CO2 blowing agent using a discharge nozzle with a tubular outlet section having vanes radially symmetrically distributed within the tubular outlet section. The resulting foam was visibly more evenly distributed, resulting in a more uniform spray pattern with less splashing and exhibiting improved adhesion to the substrate. (Aspect) (Aspect 1) 1. A nozzle suitable for dispensing a liquid foamable product, comprising: a tubular outlet section having an inlet portion and an outlet portion; the tubular outlet section has an inner wall surface defining a discharge passageway, the passageway having a centerline axis; the tubular outlet section further includes a plurality of vanes mounted on the inner wall surface parallel to the centerline axis, the vanes extending radially into the discharge passage; the vane has a length having a length dimension, a thickness having a thickness dimension, and a width having a width dimension; the thickness dimension is smaller than the width dimension, the width dimension is smaller than the length dimension, the length dimension is the distance the vane contacts the inner wall surface parallel to the centerline axis, the thickness dimension is the effective thickness of the vane at the inner wall surface perpendicular to the centerline axis, and the width dimension is the distance the vane extends from the inner wall surface into the discharge passage; A nozzle in which the vanes do not connect or touch at the centerline of the discharge passage. (Aspect 2) 10. The nozzle of embodiment 1 having three or more vanes. (Aspect 3) 3. The nozzle of embodiment 2, having 5 to 10 vanes. (Aspect 4) Aspect 4. The nozzle of any one of aspects 1 to 3, wherein the vanes are distributed radially symmetrically around the centerline of the discharge passage. (Aspect 5) Aspect 4. The nozzle of any one of aspects 1 to 3, wherein the vanes are distributed radially asymmetrically around a centerline of the discharge passage. (Aspect 6) Aspect 6. The nozzle of any one of aspects 1-5, wherein the width dimension of each vane has a maximum value at the outlet of the tubular outlet section and decreases along the length of the vane. (Aspect 7) Aspect 7. The nozzle of any one of aspects 1 to 6, wherein the thickness dimension of each vane has a maximum value at the inner wall surface and decreases radially into the discharge passage. (Aspect 8) Aspect 7. The nozzle according to any one of aspects 1 to 6, wherein the thickness dimension of each vane does not change from the inner wall surface toward the discharge passage. (Aspect 9) Aspect 9. The nozzle of any one of aspects 1-8, wherein the thickness dimension of each vane increases along the length of the vane from a minimum at the outlet portion of the tubular outlet section. (Aspect 10) Aspect 10. The nozzle of any one of aspects 1-9, further comprising a mixing chamber attached to the inlet portion of the tubular outlet section. (Aspect 11) Aspect 11. The nozzle of any one of aspects 1 to 10, wherein the outlet portion of the tubular outlet section is an outlet surface of the nozzle. (Aspect 12) 1. A method of dispensing a foamable product using a nozzle including a tubular outlet section having an inlet portion and an outlet portion, comprising: a) supplying a liquid foamable product comprising at least one foaming agent to the inlet portion of the tubular outlet section, the tubular outlet section has an inner wall surface defining a discharge passageway, the passageway having a centerline axis; the tubular outlet section further includes a plurality of vanes mounted on the inner wall surface parallel to the centerline axis, the vanes extending radially into the discharge passage; the vane has a length having a length dimension, a thickness having a thickness dimension, and a width having a width dimension; the thickness dimension is smaller than the width dimension, the width dimension is smaller than the length dimension, the length dimension is the distance the vane contacts the inner wall surface parallel to the centerline axis, and the thickness dimension is the effective thickness of the vane at the inner wall surface perpendicular to the centerline axis; the width dimension is a distance from the inner wall surface to which the vane extends into the discharge passage, the vanes do not connect or touch at the centerline of the discharge passage; The process and b) dispensing said liquid foamable product from said outlet portion of said tubular outlet section; A method comprising: (Aspect 13) 13. The method of embodiment 12, wherein the nozzle has three or more vanes. (Aspect 14) 14. The method of claim 13, wherein the nozzle has 5 to 10 vanes. (Aspect 15) Aspects 15. The method of any one of aspects 12 to 14, wherein the nozzle has vanes distributed radially symmetrically about the centerline of the discharge passage. (Aspect 16) Aspects 15. The method of any one of aspects 12 to 14, wherein the nozzle has vanes distributed asymmetrically radially about the centerline of the discharge passage. (Aspect 17) Aspects 17. The method of any one of aspects 12-16, wherein the width dimension of each vane has a maximum value at the outlet portion of the tubular outlet section and decreases along the length of the vane. (Aspect 18) Aspects 12-17. The method of any one of aspects 12-17, wherein the thickness dimension of each vane in the nozzle has a maximum value at the inner wall surface and decreases radially into the discharge passage. (Aspect 19) Aspects 12 to 18, wherein the thickness dimension of each vane in the nozzle does not change from the inner wall surface toward the discharge passage. (Aspect 20) Aspects 20. The method of any one of aspects 12-19, wherein the thickness dimension of each vane increases along the length of the vane from a minimum at the outlet portion of the tubular outlet section. (Aspect 21) Aspect 21. The method of any one of aspects 12-20, wherein the nozzle further comprises a mixing chamber attached to the inlet portion of the tubular outlet section. (Aspect 22) 22. The method of any one of aspects 12 to 21, wherein the blowing agent is carbon dioxide.

Claims

1. 1. A nozzle suitable for dispensing a liquid foamable product, comprising: a tubular outlet section having an inlet portion and an outlet portion; the tubular outlet section has an inner wall surface defining a discharge passageway, the passageway having a centerline axis; the tubular outlet section further includes a plurality of vanes mounted on the inner wall surface parallel to the centerline axis, the vanes extending radially into the discharge passage; the vane has a length having a length dimension, a thickness having a thickness dimension, and a width having a width dimension; the thickness dimension is smaller than the width dimension, the width dimension is smaller than the length dimension, the length dimension is the distance the vane contacts the inner wall surface parallel to the centerline axis, the thickness dimension is the effective thickness of the vane at the inner wall surface perpendicular to the centerline axis, and the width dimension is the distance the vane extends from the inner wall surface into the discharge passage; A nozzle in which the vanes do not connect or touch at the centerline of the discharge passage.

2. The nozzle of claim 1 , wherein said vanes are distributed radially symmetrically about said centerline of said discharge passage.

3. A nozzle according to any preceding claim, wherein the vanes are distributed radially asymmetrically about the centre line of the discharge passage.

4. A nozzle according to any preceding claim, wherein the width dimension of each vane has a maximum value at the outlet of the tubular outlet section and decreases along the length of the vane.

5. A nozzle according to any one of claims 1 to 4, further comprising a mixing chamber attached to the inlet portion of the tubular outlet section.

6. A nozzle according to any preceding claim, wherein the outlet portion of the tubular outlet section is the outlet face of the nozzle.

7. 1. A method of dispensing a foamable product using a nozzle including a tubular outlet section having an inlet portion and an outlet portion, comprising: a) supplying a liquid foamable product comprising at least one foaming agent to the inlet portion of the tubular outlet section, the tubular outlet section has an inner wall surface defining a discharge passageway, the passageway having a centerline axis; the tubular outlet section further includes a plurality of vanes mounted on the inner wall surface parallel to the centerline axis, the vanes extending radially into the discharge passage; the vane has a length having a length dimension, a thickness having a thickness dimension, and a width having a width dimension; the thickness dimension is smaller than the width dimension, the width dimension is smaller than the length dimension, the length dimension is the distance the vane contacts the inner wall surface parallel to the centerline axis, and the thickness dimension is the effective thickness of the vane at the inner wall surface perpendicular to the centerline axis; the width dimension is a distance from the inner wall surface to which the vane extends into the discharge passage, the vanes do not connect or touch at the centerline of the discharge passage; The process and b) dispensing said liquid foamable product from said outlet portion of said tubular outlet section; A method comprising:

8. The method of claim 7 , wherein the nozzle further comprises a mixing chamber attached to the inlet portion of the tubular outlet section.

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